Traction Studs And Outsoles

ABSTRACT

A traction stud comprises: a carrier comprising a post, a hollow defined by the post that opens at a distal end of the post, and a multi-pronged flange at a proximal end of the post; and a tip bonded in the hollow and extending past the distal end of the post. The carrier may be metal and/or the tip is ceramic. The multi-pronged flange may comprise two or more prongs, each prong having a first face, a second face, a thickness, and one or more holes extending from the first face to the second face, wherein the first and second faces are substantially perpendicular to the post. Outsoles comprise the traction studs and boots and/or overshoes comprise the outsoles. The traction studs are securely retained by polymeric material of the outsoles. The studs penetrate and/or grip slippery surfaces such as ice and packed snow.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.62/394,913, filed Sep. 15, 2016, the entire disclosure of which ishereby incorporated by reference herein.

TECHNICAL FIELD

The present disclosure generally relates to traction studs and tofootwear having outsoles including the studs suitable for traction underslippery and/or icy conditions. In particular, traction studs comprise acarrier comprising a post, a hollow defined by the post that opens at adistal end of the post, and a multi-pronged flange at a proximal end ofthe post; and a tip bonded in the hollow and extending past the distalend of the post.

BACKGROUND

Icy conditions can present risks of slip and fall injuries to personswho work and recreate on them. To enhance traction on ice and packedsnow, outsoles of boots or overshoes are often provided with tractionstuds. Studs are desirably heavy duty to penetrate and grip slipperysurfaces. Even so, over time and with use, studs are subject tobreakage, separation from the outsole, and material degradation.

There is an ongoing need to provide traction outsoles that are heavyduty and remain effective to penetrate and/or grip slippery surfacessuch as ice and packed snow for the effective life of footwear such asboots and overshoes.

SUMMARY

Provided are traction studs that are securely retained by polymericmaterial of footwear outsoles. The studs penetrate and/or grip slipperysurfaces such as ice and packed snow.

An aspect is a traction stud for boots and overshoes comprising: acarrier comprising a post, a hollow defined by the post that opens at adistal end of the post, and a multi-pronged flange at a proximal end ofthe post; and a tip bonded in the hollow and extending past the distalend of the post. The carrier may be metal, the tip may be ceramic, orboth. In one or more embodiments, the carrier comprises a steel materialand the tip comprises tungsten carbide.

The multi-pronged flange may comprise two or more prongs, each pronghaving a first face, a second face, a thickness, and one or more holesextending from the first face to the second face, wherein the first andsecond faces are substantially perpendicular to the post. The post andthe tip may be coaxial. The carrier may be a unitary construction.

The tip may comprise a ceramic material selected from the groupconsisting of: an oxide of aluminum, zircon, silicon, titanium,tungsten; a metal carbide or nitride of aluminum, silicon, titanium,tungsten, zircon; or mixtures thereof, or a metal alloy selected fromthe group consisting of: bronze, brass, copper-nickel alloy,copper-aluminum alloy, or copper-beryllium alloy.

Another aspect is an outsole of a boot for traction in slipperyconditions comprising: an outsole body comprising a first polymericmaterial and having an external surface; and a plurality of tractionstuds according to any embodiment disclosed herein embedded in the firstpolymeric material and protruding from the external surface. The firstpolymeric material may comprise a thermoplastic polyurethane (TPU). Theexternal surface may comprise one or more integrally-formed featuresselected from the group consisting of: a toe, a heel, a heel strike,cleats, and bobs. A first plurality of studs may be located in aplurality of cleats, a second plurality of studs may be located in aplurality of bobs, or both.

A further aspect is a boot or overshoe comprising an upper and anyoutsole disclosed herein affixed to the upper. The boot or overshoe mayfurther comprise a midsole comprising a second polymeric materiallocated between the outsole body and the upper. The second polymericmaterial may comprise polyurethane. The midsole may comprise a midsoleedge, a midsole lip, a toe cap, and a heel counter.

Another aspect is a boot or overshoe for traction in slippery conditionscomprising: an upper comprising a waterproof material; an outsolecomprising an outsole body comprising a first polymeric material andhaving an external surface and a plurality of traction studs embedded inthe first polymeric material and protruding from the external surface,each stud comprising a carrier comprising a post, a hollow defined bythe post that opens at a distal end of the post, and a multi-prongedflange at a proximal end of the post; and a tip bonded in the hollow andextending past the distal end of the post; and a midsole comprising asecond polymeric material, the midsole direct-attaching the upper andthe outsole. The waterproof material may comprise a polyurethane-coatednylon, the first polymeric material may be a TPU, the second polymericmaterial may be a polyurethane, the carrier may comprise a steel, andthe tip may comprise tungsten carbide. The boot or overshoe may furthercomprise one or both of a heel counter and a toe cap integral to themidsole.

In another aspect, provided is a method of making a boot or overshoe fortraction in slippery conditions, the method comprising: obtaining aplurality of traction studs, each stud comprising a carrier comprising apost, a hollow defined by the post that opens at a distal end of thepost, and a multi-pronged flange at a proximal end of the post; and atip bonded in the hollow and extending past the distal end of the post;forming an outsole by injection molding a first polymeric material intoa first mold cavity retaining the plurality of studs; and affixing anupper to the outsole. The carrier may be metal, the tip may be ceramic,or both. Affixing the upper to the outsole may comprise direct injectinga second polymeric material into a second mold cavity retaining theoutsole and the upper thereby forming a midsole that direct-attaches theupper and the outsole.

Another aspect is a method of providing traction in slippery conditions,the method comprising: forming any boot or overshoe disclosed herein;and wearing the boot or overshoe for transport on the slippery surfaces.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side view of a traction stud;

FIG. 2 is a schematic front view of an outsole comprising a plurality oftraction studs; and

FIG. 3 is a plan side view of an overshoe or boot comprising an outsolecomprising a plurality of traction studs.

DETAILED DESCRIPTION

Traction studs disclosed herein have an advantage in that amulti-pronged flange is used to improve continuity within the structureof a polymeric/rubber outsole. That is, the use of more than one prongat the base of a post holding a tip allows for smaller and more spaceddistances where the material of the outsole is interrupted. The use ofone or more holes in the prongs through a thickness from face-to-faceallows for the outsole material to be continuous not only above andbelow the faces, but therethrough. Prior art studs offer only a singleflange at the base of a post, which results in a relatively large areaof disrupted material and contact only above and below the flange faces(not through them). Upon wear and tear of the prior art studs andoutsoles, the studs loosen and can dislodge from the outsole, whichdiminishes ice traction performance.

Boots and overshoes provided herein have an advantage in that theiroutsoles utilize traction studs having a multi-pronged flange that issecurely embedded in the material of the outsole.

Reference herein to “stud” refers to a structure that provides aprotrusion from a surface of an outsole. The stud is usually a differentmaterial from the outsole.

A “cleat” is a feature of an outsole, which is integral to a body of theoutsole protruding from a surface of the outsole for traction purposes.

A “bob” is a specific type of cleat, having a round shape.

An array of cleats and bobs constitutes a tread pattern.

Before describing several exemplary embodiments of the invention, it isto be understood that the invention is not limited to the details ofconstruction or process steps set forth in the following description.The invention is capable of other embodiments and of being practiced orbeing carried out in various ways.

Turning to the figures, FIG. 1 is a schematic side view of a tractionstud 100. The stud 100 comprises a carrier 102 and a tip 104. In one ormore embodiments, the carrier is metal and/or the tip is ceramic. Thecarrier 102 comprises a post 106 having a distal end 118 and a proximalend 110 and a flange 108. The carrier 102 may be a unitary construction,where the post 106 and flange 108 are one piece, being formed of anymaterial that is suitable for outdoor use under wet, icy and/or slipperyconditions. For example, materials that are non-corrosive andnon-rusting are preferable. A preferred metal material is steel.Exemplary steel materials, include stainless steel, or a carbon steelsuch as carbon steel T14 which is a hardened and tempered steel, whichmay have an electrolytic coating to protect against corrosion andenhance durability. Suitable electrolytic coatings include but are notlimited to copper (99% purity) and/or nickel (99% purity).

The post 106 has a length “B” and a hollow (not numbered) that providesan opening at its distal end 118 in which the tip 104 resides. The tipis securely bonded in the hollow. The hollow has a length that isshorter than the post's length “B”. The tip 104 extends past the distalend 118 of the post 106 for a distance of “A” as shown in FIG. 1. Thehollow and likewise, the tip 104 are generally coaxial with the post 106for symmetry. The tip may comprise any suitable material for outdoor useunder wet, icy and/or slippery conditions. For example, materials thatare non-corrosive and non-rusting are preferable. Non-sparking materialsmay also be suitable. The tip may comprise a ceramic material selectedfrom the group consisting of: an oxide of aluminum, zircon, silicon,titanium, tungsten; a metal carbide or nitride of aluminum, silicon,titanium, tungsten, zircon; or mixtures thereof. Preferably, the ceramictip is tungsten carbide. The tip may comprise a metal that is iron-free.The tip may comprise a metal alloy such as bronze, brass, copper-nickelalloy (Monel metal), copper-aluminum alloy (aluminum bronze), orcopper-beryllium alloy (beryllium bronze).

Dimensions of the carrier and tip depend on the application. Generally,the tip extends from the distal end of the post far enough to providetraction and not too far as to be prone to breakage. The post is sizedto protrude from an external surface of an outsole and to providestructure to the tip. The flange is sized and the holes are designed toprovide surface area for the outsole material to adhere and connect toitself. In one or more non-limiting embodiments, the post 106 has alength B in the range of 7-11 mm±2%. In one or more non-limitingembodiments, the tip 104 extends past the distal end 118 for 1-1.15mm±1%. The tip 104 may have a total length in the range of 6-6.2 mm±1%.

The flange 108 is at the proximal end 110 of the post 106, preferablyhaving two or more prongs 116 a, 116 b, 116 c, 116 d, i.e., beingmulti-pronged. The flange 108 has a thickness of “C” and a width at itswidest part of “E”. In one or more embodiments, the thickness C is inthe range of 1-1.2±1% and the width E is in the range of 9.8-10.0 mm±2%.Total height of the stud 100 is “D”, which equals A+B+C, and may be inthe range of 9-9.35±1%. Each prong has a first face 112 and a secondface (not shown) opposite the first face 112 separated by the thicknessC. The flange 108 is substantially perpendicular to the post in thatthere is a nominal 90°±5% angle where the flange 108 meets the proximalend of the post 110, allowing for tolerance errors machining and/ormolding. Each prong 116 a-d comprises one or more holes 114 extendingfrom the first face 112 to the second face. The prongs preferably havethe same number of holes each for symmetry, but should a need arise, thenumber of holes per prong may vary. The holes may be of any diameter andcross-section shape as desired. The holes are sized and located tofacilitate manufacture of the studs themselves and also for readilyreceiving injected polymer so that upon formation, the outsole materialis above, below, and through the prongs of the stud, which acts as alocking mechanism to hold the studs in place.

FIG. 2 is a schematic front view of an outsole 200 comprising an outsolebody 202 and a plurality of traction studs 100 embedded therein. Theoutsole body 202 has an external surface 204, which faces the groundduring use. Portions of the external surface 204, primarily projectingportions, are in contact with the ground during use. The outsole body202 comprises a polymeric material that is suitable for outdoorconditions. A preferred polymeric material for the outsole body is athermoplastic polyurethane. The outsole 200 is formed by injectionmolding the polymeric material into a mold cavity of a desired treadpattern having projecting features, some of which retain the tractionstuds 100. The polymeric material flows around the multi-pronged flangeand through the one or more holes of the prongs, which upon curing andsolidifying results in embedding the studs 100 in the polymericmaterial. Without intending to be bound by theory, it is thought that areinforcement of the studs to the outsole is formed by the flow ofpolymer through the holes of the prongs, which forms connecting polymermaterial to the polymer material that is on both sides of the prongs.This results in securely retaining the studs as compared to the priorart.

A mold for the outsole is prepared according to desired design features.One or more integrally-formed features of the outsole tread include butare not limited to: a toe 208, a heel 210, a heel strike 212, one ormore cleats 214, and one or more bobs 216. The studs are generallyretained in one or more cleats and one or more bobs, which arethroughout the external surface 204 of the outsole body 202 includingthe heel 210. Generally, there are not studs located in the heel strikeor the toe. Placement of the studs is throughout the outsole body toensure the studs will be in contact with the ground and to providetraction during walking and striding. Preferably, the studs are instaggered positions to obtain maximum traction with the fewest studs. Inone or more non-limiting embodiments, studs may be placed along theperimeter of the outsole in cleats and in the interior in bobs. Left andright outsoles are generally mirror images of each other.

FIG. 3 is a plan side view of an overshoe or boot 300 comprising anoutsole 200, which has a plurality of traction studs 100, an upper 312,and a midsole 302. The outsole 200 is according to any disclosed herein.The upper 312 may be any suitable material for the application.Generally, the upper is waterproof. Materials for the upper include butare not limited to polymeric materials and textile or fabric materialsthat have been waterproofed. For example, the upper may be a woven nylonthat is coated with polyurethane. The upper is generally stitchedtogether and the seams are rendered waterproof. The upper may containadditional features as desired, such as reflective piping for enhancedsafety; gussets to assist in donning an overshoe; a strap to secure theovershoe during use; and a gaiter to provide extended waterproofcoverage on the leg.

The midsole 302 comprises a polymeric material that is generallydifferent from the polymeric material of the outsole, but which iscompatible to facilitate direct attachment of the outsole to the upperby injection molding. By this method, an internal waterproof membrane isnot needed to ensure waterproofing of the boot or overshoe. The midsolemay comprise a polyurethane. In one or more embodiments, to form themidsole 302, a mold cavity holds a pre-fabricated outsole 200 and apre-fabricated upper 312. Polyurethane is injected to form the midsole302 having a midsole edge 304, which provides a boundary with theoutsole 200. In this embodiment, a midsole lip 306 is integral to toecap 308 and heel counter 310, while providing a boundary with the upper312 where it meets the upper 312. The midsole 302 may further have oneor more features including but not limited to: a toe cap 308 and a heelcounter 310, which may be designed to accommodate various applications.Generally, the toe cap 308 and the heel counter 310 are formedintegrally with the midsole. In a detailed embodiment, the midsole 302comprises: the midsole edge 304, the midsole lip 306, the toe cap 308,and the heel counter 310.

Reference throughout this specification to “one embodiment,” “certainembodiments,” “various embodiments,” “one or more embodiments” or “anembodiment” means that a particular feature, structure, material, orcharacteristic described in connection with the embodiment is includedin at least one embodiment of the disclosure. Thus, the appearances ofthe phrases such as “in one or more embodiments,” “in certainembodiments,” “in various embodiments,” “in one embodiment” or “in anembodiment” in various places throughout this specification are notnecessarily referring to the same embodiment of the disclosure.Furthermore, the particular features, structures, materials, orcharacteristics may be combined in any suitable manner in one or moreembodiments.

Although the disclosure herein provided a description with reference toparticular embodiments, it is to be understood that these embodimentsare merely illustrative of the principles and applications of thedisclosure. It will be apparent to those skilled in the art that variousmodifications and variations can be made to the present disclosurewithout departing from the spirit and scope thereof. Thus, it isintended that the present disclosure include modifications andvariations that are within the scope of the appended claims and theirequivalents.

What is claimed is:
 1. A traction stud for boots and overshoescomprising: a carrier comprising a post, a hollow defined by the postthat opens at a distal end of the post, and a multi-pronged flange at aproximal end of the post; and a tip bonded in the hollow and extendingpast the distal end of the post.
 2. The traction stud of claim 1,wherein the carrier is metal, the tip is ceramic, or both.
 3. Thetraction stud of claim 1, wherein the multi-pronged flange comprises twoor more prongs, each prong having a first face, a second face, athickness, and one or more holes extending from the first face to thesecond face, wherein the first and second faces are substantiallyperpendicular to the post.
 4. The traction stud of claim 1, wherein thepost and the tip are coaxial.
 5. The traction stud of claim 1, whereinthe carrier is a unitary construction.
 6. The traction stud of claim 1,wherein the tip comprises a ceramic material selected from the groupconsisting of: an oxide of aluminum, zircon, silicon, titanium,tungsten; a metal carbide or nitride of aluminum, silicon, titanium,tungsten, zircon, or mixtures thereof; or a metal alloy selected fromthe group consisting of: bronze, brass, copper-nickel alloy,copper-aluminum alloy, or copper-beryllium alloy.
 7. The traction studof claim 1, wherein the carrier comprises a steel material and the tipcomprises tungsten carbide.
 8. An outsole of a boot for traction inslippery conditions comprising: an outsole body comprising a firstpolymeric material and having an external surface; and a plurality oftraction studs of claim 1 embedded in the first polymeric material andprotruding from the external surface.
 9. The outsole of claim 8, whereinthe first polymeric material comprises a thermoplastic polyurethane(TPU).
 10. The outsole of claim 8, wherein the external surfacecomprises one or more integrally-formed features selected from the groupconsisting of: a toe, a heel, a heel strike, cleats, and bobs.
 11. Theoutsole of claim 10, wherein a first plurality of studs is located in aplurality of cleats, a second plurality of studs is located in aplurality of bobs, or both.
 12. A boot or overshoe comprising an upperand the outsole of claim 8 affixed to the upper.
 13. The boot orovershoe of claim 12 further comprising a midsole comprising a secondpolymeric material located between the outsole body and the upper. 14.The boot or overshoe of claim 13, wherein the second polymeric materialcomprises polyurethane.
 15. The boot or overshoe of claim 13, whereinthe midsole comprises a midsole edge, a midsole lip, a toe cap, and aheel counter.
 16. A boot or overshoe for traction in slippery conditionscomprising: an upper comprising a waterproof material; an outsolecomprising an outsole body comprising a first polymeric material andhaving an external surface and a plurality of traction studs embedded inthe first polymeric material and protruding from the external surface,each stud comprising a carrier comprising a post, a hollow defined bythe post that opens at a distal end of the post, and a multi-prongedflange at a proximal end of the post; and a tip bonded in the hollow andextending past the distal end of the post; and a midsole comprising asecond polymeric material, the midsole direct-attaching the upper andthe outsole.
 17. The boot or overshoe of claim 16, wherein thewaterproof material comprises a polyurethane-coated nylon, the firstpolymeric material is a TPU, the second polymeric material is apolyurethane, the carrier comprises a steel, and the tip comprisestungsten carbide.
 18. The boot or overshoe of claim 16 furthercomprising one or both of a heel counter and a toe cap integral to themidsole.
 19. A method of making a boot or overshoe for traction inslippery conditions, the method comprising: obtaining a plurality oftraction studs, each stud comprising a carrier comprising a post, ahollow defined by the post that opens at a distal end of the post, and amulti-pronged flange at a proximal end of the post; and a tip bonded inthe hollow and extending past the distal end of the post; forming anoutsole by injection molding a first polymeric material into a firstmold cavity retaining the plurality of studs; and affixing an upper tothe outsole.
 20. The method of claim 19, wherein the carrier is metal,the tip is ceramic, or both.
 21. The method of claim 19, whereinaffixing the upper to the outsole comprises direct injecting a secondpolymeric material into a second mold cavity retaining the outsole andthe upper thereby forming a midsole that direct-attaches the upper andthe outsole.
 22. A method of providing traction in slippery conditions,the method comprising: forming a boot or overshoe of claim 16; andwearing the boot or overshoe for transport on the slippery surfaces.